Simplify Your Manufacturing Operations with CLEVR

In the dynamic world of manufacturing, the key to success lies not only in efficiency but also in optimizing operational technology (OT). Every second counts, and the ability to harness and analyze the invaluable data generated by machines in real-time can make or break a factory's success. However, the challenge lies not just in collecting massive amounts of data, but in sifting through and saving the necessary information for smarter decision-making.

To meet these needs, industries are revolutionizing their approach by turning to Industrial Edge Computing, a concept that seamlessly connects the hardware on the factory floor to the cloud. This is where innovative solutions provided by Mendix, Siemens Industrial Edge and CLEVR become crucial players. In this article, we'll discuss the elements of Industrial Edge and explore how it is transforming factory management with advanced tools integration.

Understanding Siemens' Industrial Edge Ecosystem in Manufacturing

Industrial Edge Computing is a solution that seamlessly connects the hardware on the factory floor to the cloud, facilitating real-time data analysis. It effectively bridges the gap between physical machinery and digital infrastructure, enhancing both efficiency and responsiveness.

At the heart of this transformative concept is the Siemens Industrial Edge platform. This robust architecture deploys Mendix apps on Industrial Edge devices, serving as the vital link connecting Programmable Logic Controllers (PLCs) to the Siemens Industrial Edge ecosystem. This open, ready-to-use edge computing platform is ideally suited for any manufacturing floor.

The Siemens Industrial Edge platform comprises three core elements:

1. Industrial Edge Hub: This is essentially a global repository where customers can centrally distribute purchased or self-developed apps to multiple management systems, enabling the adoption of machine-as-a-service solutions. Custom applications created using low-code solutions like Mendix can be effortlessly brought into this ecosystem, bridging the gap between consumers and producers.

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2. Industrial Edge Management (Cloud): This software-as-a-service (SaaS) instance of the management system provides a customer-managed system that encompasses custom-made applications, third-party apps, and other solutions from the Industrial Edge Marketplace. It offers easy maintenance and control of edge devices and apps for production sites on a global scale.

1. Industrial Edge Device: These industrial PCs interact with machines on the shopfloor (OT) in real-time and provide access to the data they generate. Through Industrial Edge these devices get their ability to communicate, collaborate, and make informed decisions across various manufacturing units.

The Siemens Industrial Edge ecosystem simplifies the interaction between consumers and producers, effectively bridging the IT and OT gap. Built-in connectors make data easily accessible in a consumable format, paving the way for digital transformation.

The Power of Mendix and Siemens Industrial Edge Integration

Mendix, traditionally linked with manufacturing, lacked a direct connection with machines. However, this gap has been bridged with Siemens Industrial Edge (IE), creating a path to full digitalization and automation.

Siemens IE provides an ecosystem for deploying Mendix apps on Industrial Edge devices, connecting the PLC data to the Siemens IE ecosystem. This open, ready-to-use platform effectively turns raw data from the manufacturing floor into actionable insights for process optimization, predictive maintenance, risk identification, and more.

The Siemens IE ecosystem includes an edge device, edge applications, connectivity services (e.g., to the cloud with Insights-Hub), and an edge management platform, all designed for industrial manufacturers. It elegantly layers complex architecture, making it easy to deploy on any manufacturing floor.

The combination of Siemens Industrial Edge and Mendix, along with partners like CLEVR, is transforming manufacturing. It breaks down IT and OT barriers, improves machinery performance, and enables digital transformation.

How CLEVR helps in bridging the IT-OT Divide with Industrial Edge?

Software creation and machine programming are diverse, using different PLC protocols, such as ladder diagrams, structured text logic (STL), and others. As a solution provider, understanding IT and OT to build solutions is challenging, especially when OT is a new territory. Without comprehensive knowledge of both domains and a suitable framework to connect IT with OT, solution development becomes a heavy task.

Consider an industrial manufacturer producing car engine chassis. They need machine X from an original equipment manufacturer (OEM) to ensure top quality. This machine has an industrial edge device for optimal operation, risk assessment, and machine health monitoring. In this scenario, different companies can collaborate through Edge ecosystem to make informed decisions about their machinery and overall performance synchronization. Both parties control their data sharing and independently manage applications in their local app repository.

Solution partners like CLEVR can play a critical role here, they excel in developing solutions for both OEMs and manufacturers. This underscores the immense strength of domain expertise, backed by cutting-edge technology.
The outcome? A collaboration where different companies can work together, discover latent variables, and optimize machine performance. The Industrial Edge ecosystem effectively links consumers and producers, tearing down the barriers between IT and OT with its in-built connectors.

The Mendix, Siemens, CLEVR partnership is pushing manufacturing into a new era. Seize this digital transformation with real-time data, optimized machinery, and IT-OT collaboration. Reach out to CLEVR to learn how we can help you with our expertise, modernize your operations. Together, let's create an advanced, streamlined, efficient manufacturing landscape. In other words, let’s Build Tomorrow Together.

Today's era of technological advancement has shifted digital transformation from being just a buzzword to an essential pivot for manufacturers. To safeguard their competitive advantage in the fluctuating market dynamics and the ever-evolving customer expectations, it's imperative for manufacturers to develop and execute a robust digital transformation strategy.

The relentless acceleration of technological advancements has left manufacturers at the initial stages of digital transformation. A significant hurdle impeding progress in digital projects is the misalignment between Information Technology (IT) and Operational Technology (OT). This disconnection prevents a holistic view of operations, a vital component for successful digital transformation.

The Indispensable Role of an End-to-End Ecosystem: PLM, MES and Digital Twins

This is where Product Lifecycle Management (PLM) comes into play. PLM plays a critical role in creating an effective end-to-end ecosystem by integrating systems, processes, and people seamlessly. It aids in modernizing IT and OT processes, thus constructing a much-needed bridge in the perpetually changing landscape.

The importance of PLM is emphasized by the anticipated growth of the PLM software market, projected to reach USD 9.22 billion in 2025, showing growth that signifies how instrumental PLM is in steering the journey towards successful digital transformation.

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‘We have one of the biggest and strongest partner ecosystem in our industry. And believe me one thing, we are very well on track to further expand this ecosystem and make our partners even more stronger.’

Marcel Milde- Siemens Partner

In the ongoing narrative of digital evolution, Manufacturing Operations Management (MOM) stands out as a holistic approach to oversee various aspects of the manufacturing process. Within MOM, Manufacturing Execution Systems (MES) emerge as a specific software-based solution, playing a pivotal role in shaping this narrative. Manufacturing Execution Systems (MES) have surfaced as a crucial force. By managing and monitoring work-in-process on the factory floor actively, MES provides real-time data that is invaluable in pinpointing inefficiencies, curtailing downtime, and enhancing productivity. The global MES market, expected to grow to USD 17.1 billion in 2025, testifies to its escalating importance in the digital manufacturing landscape.

The journey of digital transformation in manufacturing also introduces us to the groundbreaking concept of digital twins. These virtual replicas of physical assets are revolutionizing manufacturing processes by enhancing simulation capabilities, improving IT-OT integration, and facilitating efficient data collection. The digital twin market, projected to reach an impressive USD 48.2 billion by 2026, mirrors the profound impact of this technology on the industry.

Streamlining Processes with Low-Code (Business Process Automation)

The pivotal role of low-code in digital transformation cannot be overstated. This technology not only simplifies application development but also proves instrumental in optimizing processes within Product Lifecycle Management (PLM). By breaking down silos and fostering collaboration across various stages of product development, low-code automation enhances efficiency significantly. Its capacity to automate repetitive tasks expedites application development, ensuring swift adaptability to changes and maintaining a competitive edge. The projected growth of the global low-code development platform market, expected to reach USD 45.5 billion in 2025, emphasizes its crucial contribution to driving efficiency in the manufacturing sector.

The digital transformation in manufacturing is a complex process that involves the integration of various elements like PLM, MES, digital twins, and business process automation. These tools are not only enhancing operational efficiency but also paving the way for innovative solutions to longstanding challenges. As we delve deeper into the digital age, these technologies will persistently shape the future of manufacturing.

However, to truly succeed in this transformation, you need a trusted partner with the vision, the expertise, the people, and the solutions. CLEVR, a Siemens and Mendix partner, can be that trusted ally for you. As we continue our journey into the digital age, these technologies and partnerships will undoubtedly shape the future of manufacturing. Don't wait for the future to happen; be a part of building it. Contact us today and let your transformation begin.

Rapid technological advances, such as artificial intelligence, 5G connectivity, and robotics, are catapulting industry into a new era. In fact, these advancements are so profound they’ve been dubbed the Fourth Industrial Revolution—Industry 4.0. You’ve probably heard of it. But what is Industry 4.0, exactly?

This technological shift is reshaping the way companies operate. They’re more productive, efficient, and safer while reducing costs. Companies that adapt quickly will gain a competitive edge, but companies slow to adapt risk falling behind.

This guide will help your company get ready for the future. We’ll explain what Industry 4.0 is, how new technologies are currently applied, and how your business can prepare for the changes ahead.

Short on Time? Here’s a Brief Overview

• Industry 4.0 involves four core concepts: digitization of physical systems, increased connectivity between industrial devices, big data analysis, and advanced automation.
• Technology like the Internet of Things (IoT), artificial intelligence (AI), and digital twins drive Industry 4.0. Applications include optimizing supply chains and enhancing automation.
• Transitioning to Industry 4.0 can help companies expand despite challenges and risks.
  Preparation for Industry 4.0 is critical.
• Preparation for Industry 4.0 is critical.

The Core Concepts of Industry 4.0

Industry 4.0 is the next step in a long history of industrial advancements. It builds on earlier moves to automation and digitization and is driven primarily by advances in four key areas.

Digitization of physical systems

Physical machinery is increasingly integrated with digital systems, creating new ways to control and monitor equipment. Today, individual pieces of equipment have far more computing power than mainframe computers did during Industry 3.0.

Wireless connectivity
Equipment used in manufacturing, healthcare, energy production, mining, and other industries centralizes systems and other machines through wireless networks. It enables remote equipment monitoring and control, real-time data collection, and data sharing between devices.

Big data analysis
Companies can now collect and analyze enormous amounts of digital information about their equipment and processes. This information allows them to make more informed decisions and is foundational for new techniques like predictive analytics.

Advanced automation
Automation today is far more advanced than automation in Industry 3.0. Facilities can be automatically controlled through a combination of sensors, robots, and AI-powered decision-making tools.

The Technologies Driving Industry 4.0

Technological advances almost unthinkable just 10 or 20 years ago are driving the core changes that characterize Industry 4.0. Let’s look closer at some of these key technologies:

• Internet of Things (IoT): IoT involves wirelessly connecting physical devices—like machinery and sensors—to share data. IoT also enables connected devices to share data with centralized computer systems, which is key for collecting and analyzing vast amounts of data.
• Cloud computing: The internet has enabled data storage and processing in the cloud—off-site servers hosted in a data center and managed by another company. Cloud computing allows companies to store and process data cost-effectively and offers the flexibility to scale their computing resources as needed.
• AI: AI empowers companies to analyze all of the data they collect. It’s crucial for automating control of industrial systems, optimizing operations, robotics, and much more.
• Digital twins: Digital twins are virtual representations of a piece of equipment or a manufacturing process that can be continuously updated with real-time data. Creating and experimenting with digital twins is a cost-effective way to optimize processes and products.
• Edge computing: Edge computing involves processing data on the same device where it’s collected. It reduces processing time so automated equipment can manage real-time changes.
• Robotics: Industrial robots have gained significant precision and flexibility, aided partly by AI and edge computing. Using robots can reduce labor costs, make factories safer, and enhance product quality.

Prominent Applications of Industry 4.0

The latest technologies enable many innovations in manufacturing, logistics, and other sectors. Let’s look at four examples of how Industry 4.0 is already having an impact.

Supply chain optimization
Companies use IoT, cloud computing, and AI to manage their supply chains better. For example, manufacturers can use connected sensors to monitor the production of raw materials for a product line and AI to analyze this data in the context of product demand. The analysis allows manufacturers to predict material shortfalls or surpluses and adjust their operations accordingly.

Predictive maintenance
Businesses can also use AI and IoT to predict when equipment needs maintenance. Internet-connected sensors deliver data about a machine’s temperature, vibration patterns, acoustic signals, and more, and AI analyzes that data to find pattern changes that indicate a problem.

Autonomous systems
Companies have increasingly automated their systems, some to the point of replacing manual labor. Amazon warehouses, for example, now use robots to pick packages, reducing the need for humans to perform this time-consuming, laborious task. In addition, manufacturing sectors are using robots to take over dangerous processes, which reduces demand for labor.

The Benefits of Industry 4.0 Adoption

Industry 4.0 clearly benefits companies that lean into the change and embrace new technologies.

First, automation can dramatically enhance operational efficiency. Companies can reduce labor requirements, increase productivity, and ensure processes perform optimally at all times.

Real-time data analytics helps companies make better decisions about day-to-day operations, further enhancing efficiency. AI can also predict potential outcomes of major changes, giving managers and executives more information when faced with difficult choices.

Yet another key benefit of Industry 4.0 is the ability to implement predictive maintenance systems. Early results in manufacturing show that predictive maintenance can reduce equipment maintenance costs by up to 25% and decrease equipment downtime by up to 50%. Predictive maintenance can also enhance safety and improve product quality.

Adopting Industry 4.0 can even open new lines of business. For example, the flexibility of robotics and faster computing allows companies to offer more customization or operate small-scale product lines, which in turn helps them better meet customers’ needs.

The Challenges Businesses Face in Adopting Industry 4.0

While Industry 4.0 holds enormous promise, transitioning to this new era can be challenging for companies built around Industry 3.0 technologies. Some of the main challenges include:

• Cost: Upgrading existing technologies or purchasing new equipment and software can be expensive.
• Integrating existing equipment: Existing equipment is often not designed to interface with modern software. Integration is usually possible but can require intensive development that risks disrupting operations.
• Cybersecurity risks: Highly connected industrial systems are vulnerable to digital attacks. To mitigate these risks, companies must invest in cybersecurity systems and train employees in digital best practices.

How Businesses Can Prepare for Industry 4.0

You can prepare your company for the move to Industry 4.0 in several ways.

Assess your digital readiness

The first step is conducting a digital readiness assessment. Audit your existing systems to determine the level of development required to integrate Industry 4.0 technologies. For example, is a piece of equipment readily compatible with IoT sensors, or is a custom integration solution needed?

This assessment can help you identify low-cost opportunities for digitization. Starting your transition to Industry 4.0 with relatively easy projects can serve as a proof of concept and prepare your workforce for change.

Invest in low code software

Low code software is a development platform that dramatically reduces the need for coding to build custom integrations and automations. It uses templates, drag-and-drop interfaces, and prebuilt software components to enable non-technical employees to digitize existing systems.

Low code software can significantly reduce the cost and time required to transition to Industry 4.0. It also empowers existing employees to build necessary integrations and software tools, ensuring they have a stake in your business’s transformation.

Partner with experts

Partnering with experts who understand your sector’s specific needs and the advantages of new technologies is key to maximizing the value of digital transformation. Experts will help you identify the highest-value opportunities for digitization and assist in developing solutions tailored to your business.

Upskill employees

Training your employees on new technologies ensures your business can operate without disruption as Industry 4.0 systems come online. Training also makes employees feel included in the transition process and boosts retention.

Final Thoughts

Industry 4.0 is the next era of industrialization, and technologies like IoT, AI, robotics, and cloud computing are driving it. It promises to transform company operations, enhance productivity, and open doors to new growth opportunities. However, transitioning to Industry 4.0 can be challenging for many companies because of the cost and complexity.

Implementing low code software with an experienced partner like CLEVR can help your business navigate the transition and emerge as a leader in Industry 4.0. Check out our low code solutions to learn more.